Lenticular card and processes for making

ABSTRACT

A process for making a lenticular card including: providing an imaged transparent sheet having a first smooth side and a second side with a lenticulated region, the transparent sheet optionally having at least one printed image area on the first smooth side and a moisture cure adhesive layer over the printed image areas and non-image areas of the first smooth side, and the moisture cure adhesive layer being applied with a screen press through a screen; and combining the imaged transparent sheet on the adhesive layer side of the transparent sheet with a backing sheet by nipping the paired sheets with a nip roller. The invention also provides processes useful for preparing a lenticular card including an optional core sheet, or optional primer layers.

RELATED APPLICATIONS

This application is a continuation under 35 U.S.C. 111(a) ofInternational Application Serial No. PCT/US01/46682 filed 02 Nov. 2001and published in English as WO 02/40291 A2 on May 23, 2002, which claimspriority from U.S. Provisional Application Ser. No. 60/245,404 filed 02Nov. 2000, which applications and publication are incorporated herein byreference.

FIELD OF THE INVENTION

The present invention provides for a lenticular card, and processes forprinting and making the card. More specifically the present inventionprovides processes for the preparation of printed lenticular cardshaving desired printed image properties, physical dimensions, andphysical characteristics as described herein.

BACKGROUND OF THE INVENTION

The ability to litho-print a lenticular lens using a conventionaloff-set printing press configured with a UV Lamp is known in the art,see for example U.S. Pat. No. 6,073,854 below. The ability to adhere theprinted lens to other plastic substrates and obtain a destructive bondbetween the lens and the substrate can be intricate and difficult, seefor example, U.S. Pat. Nos. 5,473,406, and 5,532,786.

Processes for the preparation of articles with a lenticular surface areknown, reference for example the following documents.

In U.S. Pat. No. 4,414,316, issued Nov. 8, 1983, to Conley, there isdisclosed a flexible composite sheet material having a thermosetpatterned relief surface of high quality and definition which isparticularly useful for producing high quality optical sheet componentssuch as a lenticular screen sheet for producing three-dimensionalpictures and photographs. The composite sheet comprises a flexible basefilm having front and rear surfaces and a layer of a cured thermosettingpolymer overlying the front surface of the base film. The curedthermosetting polymer layer has a nonplanar outer surface defining apredetermined desired relief pattern of high quality and durability andof fine definition in the thermosetting polymer layer. See for exampleExample 1 therein.

In U.S. Pat. No. 5,466,723, issued Nov. 14, 1995, to Dotson, there isdisclosed a radiation curable adhesive composition which comprises from15 to 85 percent by weight of beta-carboxyethyl acrylate and from 85 to15 percent by weight of 2-phenoxyethyl acrylate based on the totalweight of the composition. The adhesive provides improved adhesion forlaminating a lineiform image sheet to a lenticular array sheet.

In U.S. Pat. No. 5,473,406 (apparatus), issued Dec. 5, 1995, and U.S.Pat. No. 5,532,786 (method), issued Jul. 2, 1996, both to Hassall, etal., there is disclosed an image sheet (12) coated with a radiationcurable adhesive (48) at a coating station and then laminated to alenticular array sheet (20) at a laminating station (50). A laminationof the image and array sheets is then positioned on an aligning station(56) where the lenticules of the array sheet are aligned with the imagelines (16) of the image sheet. The adhesive is set at a curing station(60).

In U.S. Pat. No. 6,073,854, issued Jun. 13, 2000, to Bravenec et al.,there is disclosed a card (10) for use as a telephone authorization cardor the like is comprised of a layer of a backing material (20) such as astiff plastic material which has some pliability. A thin sheetlenticular lens material (12) has a flat surface (14) on which isprinted selected interlaced images. On the other side of the lensmaterial is formed a plurality of lenticules (16) through which theimages are viewed. The flat side of the lenticular material is securedto one face (22) of the backing in a convenient manner. A cutting toolis used to form an opening (32) in the outer face of the lenticules anda programmed microchip (30) is inserted in the opening and secured inplace. On the outer face of the backing material a magnetic strip (40)containing magnetically encoded indicia is secured. The card is usablein a reader (R) which can scan the magnetic strip and read informationfrom the microchip to allow the user to place a telephone call orconduct other transactions.

In U.S. Pat. No. 3,264,164, issued Aug. 2, 1966, to Jerothe et al.,there is disclosed a color dynamic, three-dimensional flexible film andmethod of making the film. The film includes a transparent sheet havinga lenticulated outer surface and line printed or image opposite surface.

The above patents are incorporated by reference herein in theirentirety.

In view of limitations of available processes for preparing lenticulatedarticles, such as efficiency and cost, a need exists for improvedprocesses for the preparation of high quality lenticulated articles.

SUMMARY OF THE INVENTION

In accordance with the present invention, processes are provided for thepreparation of lenticular articles including:

A process for making a lenticular card comprising:

providing an imaged transparent sheet having a first smooth side and asecond side with a lenticulated region, the transparent sheet having atleast one printed image area on the first smooth side and a moisturecure adhesive layer over the printed image areas and non-image areas ofthe first smooth side, and the moisture cure adhesive layer beingapplied with a screen press through a screen; and

combining the imaged transparent sheet on the adhesive layer side of thetransparent sheet with a backing sheet by nipping the paired sheets witha nip roller;

A process for making a lenticular card comprising:

providing an imaged backing sheet having a first side and a second side,the backing sheet having a printed image on one side and a moisture cureadhesive layer over the printed image areas and non-image areas of theimaged side, and the moisture cure adhesive layer being applied with ascreen press through a screen; and

combining the backing sheet on the adhesive layer side with the firstside of a transparent sheet having a first smooth side and a second sidehaving a lenticulated region by nipping the paired sheets with a niproller;

A process for making a lenticular card comprising:

providing an imaged transparent sheet having a first smooth side and asecond side having a lenticulated region, the transparent sheet having aprinted image on the first smooth side and a radiation curable adhesivelayer over the printed image areas and non-image areas of the firstsmooth side, and the radiation curable adhesive layer being applied witha screen press through a screen;

activating the radiation curable adhesive by irradiating the adhesivelayer; and

combining a backing sheet with the transparent sheet on the resultingactivated adhesive layer side of the transparent sheet by nipping thepaired sheets with a nip roller; and

A process for making a lenticular card comprising:

providing an imaged transparent sheet having a first smooth side and asecond side with a lenticulated region, the imaged transparent sheethaving a printed image on the first smooth side;

providing a backing sheet with a radiation curable adhesive layer on oneside of the backing sheet, and the radiation curable adhesive layerbeing applied with a screen press through a screen;

combining the backing sheet with the imaged transparent sheet to form acomposite sheet by nipping the paired sheets with a nip roller, theadhesive layer on the smooth side of the transparent sheet beinginterposed between the backing and transparent sheets; and

irradiating the adhesive layer within the resulting composite sheet bydirecting radiation through the transparent sheet side of the compositesheet.

Thus, the present invention provides, in embodiments, economicalprocesses for making lenticular cards articles with improved properties,such as improved indestructibility, as illustrated herein.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and other objectives, features and advantages of theinvention will be apparent from the following more particulardescription of the preferred embodiments of the invention, asillustrated in the accompanying drawings.

FIG. 1 illustrates a lenticular card embodiment of the presentinvention.

FIG. 2 illustrates an embodiment of the present invention showing aperspective view of a card having a top or outer surface with both apartial lenticular area and a partial smooth area.

FIG. 3 illustrates a lenticular card embodiment of the present inventionshowing a section view of a card having both a top outer lenticularsurface and a bottom outer lenticular surface.

DETAILED DESCRIPTION OF THE INVENTION

Applicants have discovered a improved and efficient process for makingprinted pieces, such as a credit/debit cards, gift cards, security card,phone cards, business cards, novelty cards, playing cards, tradingcards, promotional cards, or like cards and which pieces include alenticulated area on one or both sides of the finished card.

Definitions

The following definitions are used, unless otherwise described.

A “destructive bond” is generally a type of adhesive bond which onceformed between two joined sheets or surfaces cannot be mechanicallyseparated or undone without accompanying destruction or damage to twojoined sheets or surfaces which destruction or damage is readily evidentto an observer or detectable by a suitable equipped detector device.

“Transparent” as used in “transparent sheet” includes clear,semi-transparent, translucent, and the like adjectives that describe theability of the sheet to either or both: transmit at least some lightenergy from a light or radiation source to the adhesive layer toeffectuate the photocuring of the adhesive, or alternatively, totransmit at least some light energy from a light or radiation source tothe image layer to permit visualization or detection of the imager by anobserver or a machine.

The terms “include”, “for example”, “such as”, and the like are usedillustratively and are not intended to limit the present invention.

The indefinite articles “a” and “an” mean “at least one” or “one ormore” when used in this application, including the claims, unlessspecifically indicated otherwise.

“Optional” or “optionally” mean that the subsequently described event orcircumstance may but need not occur, and that the description includesinstances where the event or circumstance occurs and instances in whichit does not. For example, “optionally include a magnetic stripe” meansthat the magnetic stripe may be present but need not be present, and thedescription includes situations where the magnetic stripe is includedand situations where the magnetic stripe is not included.

“Mils” or “mils” or “mil” is a unit of length equal to one thousandth(10⁻³) of an inch (0.0254 millimeter), used to specify, for example, thethickness of sheet materials.

The present invention provides durable phone, gift, membership, loyalty,and like cards, such as with an approximate overall thickness of about30 mils, and which cards can optionally include a magnetic stripe andoptionally can be imaged or printed by, for example, thermal or ink jetimaging methods, and which printed images optionally can be furtherencoded. Such cards have traditionally been made by, for example,compression lamination to meet ISO specifications. In a desire todifferentiate themselves card-marketers and end-users desire cardformats and appearance features with interesting visual effects.Examples include holographic film, clear cards, gift cards, and thelike. The ability to efficiently produce cards having either or both anapparent 3-dimensional (3D) and an animating effect through a lenticularlens layer is desirable. Fulfilling the requirements that the card: hasabout 30 mil total thickness; has an encodable magnetic stripe; isthermally or ink jet imageable; and can be produced economically is aformidable challenge. See for example, ISO/IEC 7810:1995(E)“Identification Cards—Physical Characteristics” and ISO/IEC7816-1:1987(E) “Identification Cards—Integrated circuit(s) cards withcontacts.”

Currently available methods can provide a lens sheet or lenticulatedsheet array, which can vary in thickness, for example, from about 5 milsto about 35 mils, and from about 10 mils to about 30 mils. The thicknessof the extruded lenticular lens layer is suggested by the formula:r=C×forr=[(n′−n)/n′]×fwhere r is the radius of curvature of a lenticular lens, C is aconstant, f is the focal length of optimal focus thickness for theplastic, n′ is the index of refraction of the lens constructionmaterial, such as an extruded plastic, and n is index of refraction ofair. From the formula it is evident that the thicker the plastic thelower the pitch or lenticules per inch (LPI). The lower the pitch, themore coarse the lens. A course lens can give undesirable lens effects,for example, distortion of an underlying image. The desired pitch for acard of approximately 3⅜″×2-⅛″ is for example between about 70 LPI andabout 100 LPI. A coarser lens would require image graphics and text besignificantly large, to avoid lens effects, and which lens effects aregenerally not desired by graphic designers. Thus to run a higher pitchlens a lenticular sheet plastic would need to be, for example, between15 to about 20 mils thick and would need a white opaque sheetconstructed of, for example, plastic mounted to the back of the lens tobring the card to a total thickness of about 30 mils. The opacity of theplastic backing sheet mounted to the back of the lens sheet, inembodiments, should to be sufficiently opaque so as not to exhibit“show-through”, that is, an image printed on the back of the plasticbacking sheet should not be visible to an observer viewing the frontsurface of the lenticular card through the lenticular or smooth areas.The plastic backing sheet should also preferably be thermally imageableand constructed of a material that can be hot stamped, such as with anencodable magnetic stripe. Generally, for the card to be thermallyimageable, the surface to be imaged should be very smooth and theplastic must be able to withstand the elevated temperatures of thethermal imaging process. Thermal imaging processes works well on, forexample, laminated vinyl, polyester or co-polyester, such aspolyethylene terephthalate glycol (PETG) and amorphous polyethyleneterephthalate (APET, also known as poly(oxyethyleneoxyterephthaloyl)).Suitable polyesters, such as PETG 6763 and APET 9921, are commerciallyavailable in lenticulated from, for example, Vinyl Plastics, Inc.,Sheboygan Falls, Wis. See also EASTAPAK polyester 9921 and relatedmaterials from Eastman Chemical, affiliated or alternative suppliers.Clear PVC lenticular sheet material and PVC backing sheet material,commercially available from Goex, Janesville, Wisc., were found to be apreferred materials because of their superior destructive bonding andimaging properties. UV curable Dymax adhesive material, commerciallyavailable from Dymax Corporation, was found to be a superior bondingadhesive, especially with PVC materials. Moisture cure adhesives werefound to provide satisfactory bonding properties with polystyrene orpolyester materials and was additionally advantaged by lower costcompared to the Dymax adhesive.

SUNCURE inks is a line of inks, commercially available from SunChemical, Carlstadt, N.J., and are examples of UV curable printing inkssuitable for use in the present invention. Other inks suitable for usein the present invention are commercially available from, for example,Flint Inks, St. Paul, Minn.

Bonding the printed lens sheet and the opaque vinyl or polyester backersheet proved cumbersome or resulted in product pieces with inferiorquality, for example lacking the above mentioned indestructibilityproperty, using prior art bonding methods. In the present invention, thedesired bond can be, for example, an adhesive that dries to a solid andis destructive to the lens sheet, the optional core sheet if present,and the backer sheet if subsequent separation is attempted. Thus theprocesses of the present invention can further provide secure cardarticles which are either or both tamper resistant and tamper evident.In the present invention, the resulting card articles preferably satisfyone or more of the specification standards in the above mentionedISO/IEC 7810. The present invention provides improved and alternativeapproaches to making lenticular cards having high quality printed imagesand which images can be, for example, printed externally, such as, on anopaque backing sheet, such as a bar code or a magnetic stripe, andprinted internally and viewable through the either the lenticular or thesmooth regions of the transparent or translucent front surface sheet.

DESCRIPTION OF PREFERRED EMBODIMENTS

The following examples in conjunction with the accompanying figuresprovide illustrative and representative procedures for preparing cardarticles of the present invention. In embodiments the present inventionprovides a process for making a lenticular card comprising:

providing an imaged transparent sheet having a first smooth side and asecond side with a lenticulated region, the transparent sheet having atleast one printed image area on the first smooth side and a moisturecure adhesive layer over the printed image areas and non-image areas ofthe first smooth side, and the moisture cure adhesive layer beingapplied with a screen press through a screen; and

combining the imaged transparent sheet on the adhesive layer side of thetransparent sheet with a backing sheet by nipping the paired sheets witha nip roller.

In embodiments the present invention also provides a process for makinga lenticular card comprising:

providing an imaged backing sheet having a first side and a second side,the backing sheet having a printed image on one side and a moisture cureadhesive layer over the printed image areas and non-image areas of theimaged side, and the moisture cure adhesive layer being applied with ascreen press through a screen; and

combining the backing sheet on the adhesive layer side with the firstside of a transparent sheet having a first smooth side and a second sidehaving a lenticulated region by nipping the paired sheets with a niproller.

In the above processes the adhesive layer can be, for example, activatedprior to combining the sheets. The activation of the adhesive can, forexample, displace solvent from the adhesive layer and shorten theadhesive cure time and provide in some instances improved destructivebonding. The above processes can further comprise post-curing theadhesive layer with heating.

In embodiments the present invention provides a process for making alenticular card comprising:

providing an imaged transparent sheet having a first smooth side and asecond side having a lenticulated region, the transparent sheet having aprinted image on the first smooth side and a radiation curable adhesivelayer over the printed image areas and non-image areas of the firstsmooth side, and the radiation curable adhesive layer being applied witha screen press through a screen;

activating the radiation curable adhesive by irradiating the adhesivelayer; and

combining a backing sheet with the transparent sheet on the resultingactivated adhesive layer side of the transparent sheet by nipping thepaired sheets with a nip roller.

In embodiments the present invention provides a process for making alenticular card comprising:

providing an imaged transparent sheet having a first smooth side and asecond side with a lenticulated region, the imaged transparent sheethaving a printed image on the first smooth side;

providing a backing sheet with a radiation curable adhesive layer on oneside of the backing sheet, and the radiation curable adhesive layerbeing applied with a screen press through a screen;

combining the backing sheet with the imaged transparent sheet to form acomposite sheet by nipping the paired sheets with a nip roller, theadhesive layer on the smooth side of the transparent sheet beinginterposed between the backing and transparent sheets; and

irradiating the adhesive layer within the resulting composite sheet bydirecting radiation through the transparent sheet side of the compositesheet.

In the above process involving irradiation, the irradiating can beaccomplished, for example, by focused or unfocused ultraviolet light.The irradiating can cure the adhesive, for example, in from about 1 toabout 20 seconds. Irradiation conditions can depend upon a number ofprocess variables and the configuration of mechanical and processingcomponents employed, such as web width and speed, lamp power ratings,lamp proximity, and the like considerations. Exemplary irradiationapparatus and conditions can be, for example: two metal halideultraviolet (UV) lamps which deliver about 400 Watts per inch to a 42inch wide web or belt of a lithographic press operating at from about 40to about 100 feet per minute; or two medium pressure mercury vaporultraviolet (UV) lamps which deliver about 300 Watts per inch to a 30inch wide web or belt of a lithographic press operating at from about 50to about 120 feet per minute. Other optimal web or belt speeds can bereadily determined by trial and error in view of variability observed incure rates based on, for example, differences in ink colors selected andtheir UV light adsorption properties, ink area coverage, and lampintensity, and the like considerations, with the aid of, for example, aunicure radiometer by measuring power per unit area, such as in therange of about 0.25 Joules per square centimeter to about 2.0 Joules persquare centimeter. In embodiments the radiation or photo-cure adhesivecan be, for example, a UV pressure sensitive adhesive (PSA), which can,for example, post cure to a tough, durable but flexible solid. Inembodiments the photo-cure adhesive can be, for example, electron beamcurable.

In the foregoing processes the backing sheet alternatively can be asecond transparent sheet, for example, identical or similar to the firsttransparent sheet to provide a two-sided or double-sided transparentarticle with an optional transparent, semi-transparent or opaque core.The alternative transparent backing sheet can be a second sheet having afirst smooth side and a second side having a lenticulated region andwherein the first smooth side of the transparent backing sheetoptionally contacts the adhesive layer before combining with the imagedtransparent sheet. Thus the present invention in embodiments provides aprocess for making an lenticular card article comprising:

providing a first transparent sheet having a first smooth side and asecond side with a lenticulated region, the transparent sheet having aprinted image on the first smooth side and an adhesive layer over theprinted image areas and non-image areas of the first smooth side; and

combining by nipping a second transparent sheet having a first smoothside and a second side with a lenticulated region together with thefirst transparent sheet on the adhesive layer side of the firsttransparent sheet, wherein the first smooth side second transparentsheet contacts the adhesive layer.

In the above-mentioned processes the backing sheet can be, for example,paper, resin, plastic, glass, rubber, metal, alloy, or combinationsthereof. In the abovementioned processes the backing sheet can be, forexample, polystyrene, polyvinyl chloride (PVC), PVC laminatedpolystyrene, compression laminated polystyrene, compression laminatedPVC, polyester, polyolefins such as polyethylene, polypropylene, and thelike, ABS, acrylics, epoxies, polyurethanes, polycarbonates, orcombinations or laminates thereof. In the above mentioned processes thebacking sheet can be, for example, opaque, transparent orsemi-transparent. In the abovementioned processes the transparent sheetcan be configured in the processing machinery as a continuous web.Similarly, the backing sheet can be configured in the processingmachinery as a continuous web. The above mentioned processes canoptionally further comprise applying a primer layer to the smooth sideof the transparent sheet prior to applying an image layer or theadhesive layer. The above mentioned processes can optionally furthercomprise applying a primer layer to the backing sheet prior to applyingan image layer or the adhesive layer. The above mentioned processes canoptionally further comprise applying a primer layer to the backing sheetafter applying an image layer or the adhesive layer. Various primer oradhesion promoter compositions are commercially available, and oneskilled in the art can readily select a particular adhesion promotercomposition for use in the present invention depending upon, forexample, the composition of the base film layers contacted and theparticular formulation of the adhesive selected, such as athermo-setting resin. An example of a primer layer is 16330 UV curableprimer containing a benzophenone initiator, which primer is commerciallyavailable from Northwest Coatings Corp., Oak Creek, Wis. The primerlayer when applied to the lenticular sheet or backing sheet can providesuperior adhesion of the ink and adhesive layer to either sheet andprovide a superior destructive bond between adjacent layers. In theabove mentioned processes the transparent sheet can be, for example,from about 10 mils to about 26 mils thick and the backing sheet can befrom about 4 mils to about 20 mils thick. The printed image areas arepreferably printed in “reverse-read” or “wrong-read” format, that is,reversed, backwards, or mirror image, such that the resulting image whenviewed through the outer surface of the transparent lenticular sheet byan observer or machine sensor is “right-read” such that the highestpossible original image fidelity is retained in the observed printedimage. The printed image areas preferably include a colored ink, forexample, one or more conventional litho-ink formulations or UV curableinks. The printed image areas can include one or many colored inks, suchas from 2 to about 10 different colored inks, for example, with a singleprimary color(R, G, B), four color process color (C, M, Y, K), white(W), a custom or spot color, such as those known colors available fromPANTONE®, and the like suppliers, and combinations thereof.

In the above mentioned processes the adhesive can be applied to eitheror both the transparent sheet or the backing sheet with any suitablemeans, for example, a roll coater, spray coater, a curtain coater, andlike devices, and preferably a screen press through a screen.

In the above mentioned processes the nipping the paired sheets with anip roller can be accomplished, for example, with a nip roller pairwhich applies, for example, from about 10 to about 1,000 p.s.i. Theapplied pressure can be from about 0 to about 10 bar, for example, atypical and suitable operating pressure is from about 7 to about 8.5bar. The above processes can further include an optional core sheetinterposed between the transparent sheet and the backing sheet and asillustrated herein. The core sheet can be transparent, semi-transparent,or opaque. The above processes can further include where the resultingcombined sheets are cut or punched into individual finished pieces, forexample, with an on-line slitter or punch press.

In embodiments the present invention provides a lenticular card preparedby the process according to any one of the above mentioned processescomprising:

an imaged transparent sheet having a first front surface with a smoothregion and a lenticulated region, and a second rear surface bearing animage;

a core sheet bonded to the transparent sheet with an adhesive; and

a backing sheet bonded to the core sheet with an adhesive.

The lenticular card article prepared by the above process can furthercomprise where the resulting card can be a secure card article which canbe tamper resistant, tamper evident, or both, and which features areknown to those skilled in the art and which feature or features can bereadily incorporated in the manufacture of the above mentionedlenticular card article, for example, in materials of construction,processing, finishing, or application. The lenticular card articleprepared by the above process can further comprise including an image onthe non-bonded surface of the backing sheet, for example, an imageprovided on the outer surface of the card article, such as a thermalimage, an ink jet image, an encodable magnetic stripe, and the likemarking technologies.

The lenticular card article prepared by the above processes can have,for example, a thickness of from about 10 to about 40 mils, such aspreferably a thickness of about 30 mils plus or minus about 1.5 mils,and a finished trim size, for example, of about 3⅜ inches wide by about2⅛ inches high. The front surface of the transparent sheet can be, forexample, extruded and can include a front surface with both one or morelenticulated regions and one or more smooth regions. In embodiments thesurface area of the front surface of the transparent sheet can be, forexample, about one half lenticulated region and about one half smoothregion. In other embodiments the front surface can be, for example, fromabout 10 to about 75 percent lenticulated region and from about 90 toabout 25 percent smooth region.

Referring to the Figures, FIG. 1 illustrates a lenticular cardembodiment of the present invention. Backing sheet 20, for example, anopaque or clear plastic such as a vinyl laminate layer, is coated withan adhesive layer 30, for example but not limited to, a glue or resinformulation. An optional core sheet 35(not shown), for example, anopaque or clear plastic sheet, can be situated between adhesive layer 30and image layer 40. It is understood that when an optional core sheet 35is present a second adhesive layer 37 (not shown) is preferred betweencore sheet 35 and the image layer 40. Image layer 40 can be, forexample, a curable ink. The lenticular top sheet 50 can be, for example,a clear plastic sheet. An optional primer layer (not shown) can beinterposed between layers 20-30, 30-40, or 40-50.

In FIG. 2 there is shown a perspective view of an exemplary card 200having a top or outer surface with both a partial lenticular area and apartial smooth area. The partial lenticulated surface area can be formedby limiting or restricting the lenticulation formation process, forexample, to one side, to restricted areas of the top surface of thecard, and like approaches. Card 200 is shown with a portion of the topsurface with partial lenticulated surface area 220, and a portion of thetop surface with a partial smooth surface area 230.

FIG. 3 shows a sectional view of a card 300 having a dual or two-sidedlenticular outer surface 310, that is where both the top outer surfaceand a bottom outer surface are partially or completely lenticular orlenticulated. The lenticular top outer surface 310 and the lenticularbottom outer surfaces 310 can be transparent or translucent andconstructed of, for example, a clear plastic. Printed image layer 320can be, for example, a conventional based printing ink or a UV curableink or inks. Adhesive layer 330 can be, for example, a resin, a glue, acurable polymer, or like materials. An optional primer layer (not shown)can be, for example, interposed between layers 310 and 320. It will bereadily understood that a card having the two-sided lenticular surfaceor lenticular surfaces as illustrated here, both sides as in FIG. 3 canhave complete or partial lenticulation areas on either or both outersurface as suggested for the one-sided lenticular surface in FIG. 2. Thecard 300 can have an optional core sheet (not shown) situated betweenadhesive layers 330 on both sides.

EXAMPLE I

Lenticulated Card No. 1.

Materials and Layer Specifications

-   Transparent Sheet: 18 mils 75 LPI APET Clear Lens-   Image Inks: 4-Color Process UV litho-inks; 1 Hit Opaque White UV    litho-ink-   Core Sheet: 10 mils white opaque polystyrene-   Adhesive: solvent based moisture urethane adhesive-   Backing Sheet: 2 mils clear PVC laminating film

The core sheet and the backing sheet were fused together in acompression laminator, for example, with a platen with thermal heatingon the 2 mils clear PVC laminating film. The adhesive failed when PVCwas used as the backing sheet, that is, the moisture cure urethane usedin this experiment did not satisfactorily bond to the PVC.

Process 1

A transparent sheet of 18 mils clear 75 LPI APET (polyester) lenticularlens was printed with an interlaced animated image matching thefrequency of the 75 LPI pitch lenticular lens. The lens used could bemade thicker or thinner and made from polymer materials other than APETpolyester, including but not limited to, for example, vinyl, PETG,polycarbonate, and like materials. Inks were printed on the transparentsheet using a litho press configured with UV Lamps, such as metal halideor mercury lamps, and irradiation from the UV lamps was used to cure theprinted inks.

One or more process colors or PANTONE® Matching System (PMS, i.e. acolor standard for non-process colors) colors can be printed inconjunction with, or in place of, the 4-color process image. The totalthickness of the imaged transparent sheet, that is, the lenticular sheetplus printed image(s) is about 18 mils. The styrene core has two bondingsurfaces. One of its surfaces contacts the adhesive that adheres thecore sheet to the printed lenticular sheet. The other surface canoptionally have one or more image colors and is laminated with a clearvinyl laminate sheet which seals the printed image colors. The laminatedvinyl surface, as either the backing sheet or optional core, provides aflat surface for additional optional thermal imaging and can withstandheat from either or both application of a hot stamped magnetic image andheat from thermal imaging processes. The styrene core sheet used was 10mils white opaque litho-grade polystyrene. A thinner or thickerpolystyrene layer can be used as long as the combined thickness of thetotal construction of the vinyl laminate, polystyrene, and the printedlenticular sheet, including all adhesive layers is approximately 30 milsto satisfy, for example, ISO/IEC card standards. The polystyrene coresheet used was matte/matte finish, however matte/gloss/or gloss/glosscombination finishes could alternatively be used. The polystyrene coresheet was printed with one or more colors on its backside with litho UVinks using, for example, a UV configured printing press. The resultingprinted or imaged polystyrene core sheet was thereafter compressionlaminated on its back side with a 2 mils thick vinyl compressionlaminating film. The film was matte/matte finish and had a heatactivated adhesive applied to one side. After compression lamination,the resulting printed and laminated polystyrene sheets were registeredand square cut to match the layback and guide of the printed lenticularsheet. Ideally, the size of the cut polystyrene and lenticular sheetshould be approximately the same size. A solvent-based (ethyl acetate)moisture cure urethane AV6370/with CA600 catalyst, available from Pierceand Stevens, was screen printed at about 50% solids on the printedlenticular sheet, using a 137 Mesh screen. However, it is noted thatother moisture cure urethane or solvent-less urethane adhesives couldalternatively be used. Although the application method for the adhesiveused was a screen press, it is noted that, for example, a roll coater,rotary letter press, rotary screen press, curtain coater, and the likecoater devices and coating methods could also be used. The combinedvinyl laminate and the polystyrene core sheets were transported,adhesive side up, with a conveyor to a heat tunnel and heated toactivate the adhesive upon reaching a temperature of about 160 degrees °F. and to flash solvents from the adhesive layer. It is readilyappreciated that some moisture cure urethanes do not need to beactivated with elevated temperatures and that room temperature may besatisfactory to accomplish activation. After solvent was removed, theadhesive was a tacky pressure sensitive adhesive. The adhesive activatedsheets were then transported to an air conditioner unit to remove excessheat that can cause distortion in the plastic. Adhesive activated sheetsmounted without this cooling step tended to warp if mounted warm.Adhesive activated sheets were then combined, that is mounted, with thelenticulated sheet and passed through a nip roller. The sheets werejogged to a common guide and gripper so the lenticulated sheet imagematched the combined backing sheet copy within a reasonable tolerance,for example, of about plus or minus 0.015 inches. The sheets werestacked and left at ambient temperatures of about 25° C. to completepolymerization and full cure. The specified full cure for the adhesivewas between about 48 and about 96 hours. Final cure was tested by thepull strength of the bond. Piece parts corresponding to cards were thenpunched from the cure composite sheet using a Print Machinery Company(PMC) die, that is a hollow steel die process. The resulting cards werethen magnetically striped by applying a one-half inch wide magnetic filmusing a Franklin Hot stamped magnetic film applicator machine. Analternative process includes laminating the styrene core using a flushmagnetic laminate film wherein the magnetic material is incorporatedinto the laminate to eliminate a separate step of applying a magneticstrip. Cards were then thermally imaged and encoded using a Data CardMachine. The adhesive bond strength of the resulting cards of thisExample was less satisfactory, for example, in curing, or with vinyl orpolyester backing materials compared with other backing materials suchas styrene.

EXAMPLE II

Lenticulated Card No. 2.

Materials and Layer Specifications

-   Transparent Sheet: 18 mils 75 LPI APET Clear Lens-   Image Inks: 4-Color Process UV litho-inks; 1 Hit Opaque White UV    litho-ink; Black Ink-UV Cured-   Adhesive: UV Curable Radcure 10PSA-B (a 2-part pressure sensitive    adhesive that cures to a solid over time)-   Core Sheet: 10 mils white opaque polystyrene core-   Adhesive: UV Curable Radcure 10PSA-B-   Backing Sheet: 2 mils clear PVC laminating film    Note: this adhesive system failed to provide a destructive bond when    PVC was used as the backing sheet.    Process 2

The process of Example I was repeated with the exception that a UVcurable pressure sensitive adhesive (PSA), Radcure 10 PSA-B, a two-partadhesive, was mixed according to manufacturer recommendations and wasscreen printed on the printed lenticular sheet, using a 137 Mesh screen.UV light irradiation was used on a 30 inch wide web running at 60 feetper minute and using two 300 Watts per inch medium pressure mercuryvapor UV lamps to activate the adhesive layer, and the adhesive becamepressure sensitive. The plastic polystyrene core was then mounted to thelenticular sheet bearing the adhesive and then combined with the vinylbacking sheet using the same adhesive used between the core and backersheet, and the combined backer, core, and lenticular sheets were nippedtogether with a nip roller. Over time, of about 24-48 hours, theadhesive post cured to a flexible solid. The sheets were transported;adhesive side up, via a conveyor to expose the adhesive to themanufacturer's recommended amount of UV light. The core sheet, 10 milslaminated on one side with 2 mils laminating film bearing the activatedadhesive, was mounted to the imaged lenticular sheet and run through anip roller. The sheets were jogged to a common guide and gripper so thelens image matched the back copy within a reasonable tolerance. Thesheets were stacked and left to polymerize to full cure. For thisadhesive a period of 48 hours was specified. Final cure strength wastested by pull strength of the bond. Piece Parts were made as punchedcards; the cards were magnetically striped and thermally imaged andencoded as in Example 1. Analysis of the resulting cards indicated thatthe UV adhesive used in this process did not work as well for curing toa vinyl or polyester backing sheets compared to a superior result for apolystyrene backing. About 500,000 cards were produced with thisprocess.

EXAMPLE III

Lenticulated Card No. 3.

Materials and Layer Specifications

-   Transparent Sheet: 18 mils 75 LPI APET Clear Lens (Alternatively, a    PVC lens was used and did not have curl as was the situation with an    APET and PVC backing combinations)-   Image Inks: 4-Color Process UV litho-inks; 1 Hit Opaque White UV    litho-ink; Black Ink-UV Cured-   Adhesive: UV activated acrylate urethane adhesive(for example Dymax    3-3094, a polyurethane oligomer mixture commercially available from    Dymax Corp., Torrington, Conn.)-   Core Sheet: 8 mils White PVC Core-   Adhesive: UV activated acrylate urethane (Dymax 3-3094)-   Backing Sheet: 2 mils clear PVC laminating film (applied to both    sides of an 8 mils white PVC core)

This adhesive worked well and provided a desired destructive bond whenPVC was used as the backing sheet which sheet could be either laminatedor non-laminated.

Process 3

The process of Example II was repeated with the exception that analternative UV curable acrylate-urethane adhesive was screen printed onthe preprinted lenticular sheet, using a 230 Mesh screen. Dymax 3-3094,a one-part adhesive was screen printed on the laminated PVC backing. Theadhesive was activated after mounting the lenticular and the core sheetstogether. The adhesive could be cured instantly, for example, by one ormore UV lamp(s) flood outputting with 365 nm wavelength of UV light,even if the radiation cure was through a partially translucent, that issemi-opaque with a relative opacity of about 30 percent, such as aprinted lenticular sheet imaged with 1-color opaque white. After the niproller, the sheets were conveyed with the printed lens on top, andexposed to the manufacturer's recommended dose of UV light. UV doselevels were determined experimentally with both 300 Watt lamps atmaximum illumination. The dose levels can depend on a number of factors,such as belt speed and the color adsorption properties and the amount ofinks used. An adhesive bond formed instantly. The sheets were stacked.Piece parts were made by punching cards. The punched cards weremagnetically striped and thermally imaged and encoded as in Example 1.To meet the ISO/IEC specification a test was to bend the corners of thecard, repeatedly back and forth, until the backing or the lens crackedbut before layers separated. The cards prepared and tested in thisexample showed no layer separation prior to cracking.

EXAMPLE IV

2-Sided Lenticulated Card No. 4.

Materials and Layer Specifications

-   Transparent Top Sheet: 18 mils 75 LPI APET Clear Lens-   Image Inks: 4-Color Process UV litho-inks; 1 Hit Opaque White UV    litho-ink;-   Black Ink-UV Cured-   Adhesive: UV activated acrylate urethane adhesive (Alternatively,    Dymax adhesive could be used here in combination with any of the    core materials, or a moisture cure adhesives such as the urethanes    could be used with, for example, polystyrene or polyester cores)-   Optional Core Sheet: 8 mils White PVC Core or an 8 mils White    polystyrene core (un-laminated)-   Optional Adhesive: UV activated acrylate urethane adhesive if    Optional Core Sheet is used-   Image Inks: 4-Color Process UV litho-inks; 1 Hit Opaque White UV    litho-ink; Black Ink-UV Cured-   Backing Sheet or Transparent Bottom Sheet: 18 mils 75 LPI APET Clear    Lens (same as the Transparent Top Sheet)    Process 4

The process of Example II was repeated with the exception that thebacker sheet was a lenticular sheet. All of the above mentionedadhesives are satisfactory here.

All cited publications, patents, and patent documents are incorporatedby reference herein in their entirety. The invention has been describedwith reference to various specific and preferred embodiments andtechniques. However, it should be understood that many variations andmodifications may be made while remaining within the spirit and scope ofthe invention.

1. A process for making a lenticular card comprising: providing an imaged transparent sheet having a first smooth side and a second side with a lenticulated region, the transparent sheet having at least one printed image area on the first smooth side and a moisture cure adhesive layer over the printed image areas and non-image areas of the first smooth side, and the moisture cure adhesive layer being applied with a screen press through a screen; combining the imaged transparent sheet on the adhesive layer side of the transparent sheet with a backing sheet by nipping the paired sheets with a nip roller; and post-curing the adhesive layer with heating.
 2. The process according to claim 1 wherein the backing sheet is a second transparent sheet having a first smooth side and a second side having a lenticulated region and wherein the first smooth side of the transparent backing sheet contacts the adhesive layer before combining with the imaged transparent sheet.
 3. The process according to claim 1 wherein the backing sheet is paper, resin, plastic, glass, rubber, metal, alloy, or combinations thereof.
 4. The process according to claim 1 wherein the backing sheet is polystyrene, polyvinylchloride (PVC), PVC laminated polystyrene, compression laminated polystyrene, compression laminated PVC, polyester, polyolefins, or combinations or laminates thereof.
 5. The process according to claim 1 further comprising including a core sheet interposed between the transparent sheet and the backing sheet wherein the core sheet bears or contacts an adhesive layer on both sides of the core sheet.
 6. The process according to claim 1 further comprising wherein the resulting combined sheets are cut or punched into individual finished pieces.
 7. A lenticular card prepared by the process according to claim 1 comprising: an imaged transparent sheet having a first front surface with a smooth region and a lenticulated region, and a second rear surface bearing an image; a core sheet bonded to the transparent sheet with an adhesive; and a backing sheet bonded to the core sheet with an adhesive.
 8. The card according to claim 7 wherein the resulting card is a secure card article which is tamper resistant, tamper evident, or both.
 9. The card according to claim 7 further comprising an image on the non-bonded surface of the backing sheet.
 10. The card according to claim 7 wherein the image is a thermal image.
 11. The card according to claim 7 wherein the image is an ink jet image.
 12. The card according to claim 7 wherein the image is an encodable magnetic stripe.
 13. The card according to claim 7 wherein the card has a thickness of from about 10 to about 40 mils.
 14. The card according to claim 7 wherein the card has a thickness of about 30 mils plus or minus about 1.5 mils.
 15. The card according to claim 7 wherein the card has a finished trim size of about 3⅜ inches wide by about 2⅛ inches high.
 16. The card according to claim 7 wherein the front surface of the transparent sheet is extruded and includes a front surface with a lenticulated region and a smooth region.
 17. The card according to claim 7 wherein the surface area of the front surface of the transparent sheet is about one half lenticulated region and about one half smooth region.
 18. The card according to claim 7 wherein the front surface is from about 10 to about 75 percent lenticulated region and from about 90 to about 25 percent smooth region.
 19. The lenticular card according to claim 7 further comprising a magnetic stripe on the non-bonded side of the backing sheet.
 20. A process for making a lenticular card comprising: providing an imaged transparent sheet having a first smooth side and a second side having a lenticulated region, the transparent sheet having a printed image on the first smooth side and a radiation curable adhesive layer over the printed image areas and non-image areas of the first smooth side, and the radiation curable adhesive layer being applied with a screen press through a screen; activating the radiation curable adhesive by irradiating the adhesive layer; and combining a backing sheet with the transparent sheet on the resulting activated adhesive layer side of the transparent sheet by nipping the paired sheets with a nip roller.
 21. The process according to claim 20 wherein the irradiating is accomplished by focused or unfocused ultraviolet light.
 22. The process according to claim 20 wherein the irradiating cures the adhesive in from about 1 to about 20 seconds.
 23. The process according to claim 20 wherein the adhesive is a UV pressure sensitive adhesive (PSA).
 24. The process according to claim 20 wherein the adhesive is electron beam curable.
 25. A process for making a lenticular card comprising: providing an imaged backing sheet having a first side and a second side, the backing sheet having a printed image on one side and a moisture cure urethane adhesive layer over the printed image areas and non-image areas of the imaged side; combining the backing sheet on the adhesive layer side with the first side of a transparent sheet having a first smooth side and a second side having a lenticulated region by nipping the paired sheets with a nip roller; and past-curing the adhesive layer with heating.
 26. A process for making a lenticular card comprising: providing an imaged transparent sheet having a first smooth side and a second side with a lenticulated region, the imaged transparent sheet having a printed image on the first smooth side; providing a backing sheet with a radiation curable urethane adhesive layer on one side of the backing sheet; combining the backing sheet with the imaged transparent sheet to form a composite sheet by nipping the paired sheets with a nip roller, the adhesive layer on the smooth side of the transparent sheet being interposed between the backing and transparent sheets; and irradiating the adhesive layer within the resulting composite sheet by directing radiation through the transparent sheet side of the composite sheet wherein the irradiating is accomplished by focused or unfocused ultraviolet light.
 27. The process according to claim 26 wherein the irradiating cures the adhesive in from about 1 to about 20 seconds.
 28. The process according to claim 26 wherein the adhesive is a UV pressure sensitive adhesive (PSA) or a UV acrylate urethane adhesive.
 29. The process according to claim 26 wherein the adhesive is electron beam curable.
 30. A lenticular card prepared by a process comprising: providing an imaged transparent sheet having a first smooth side and a second side with a lenticulated region, the transparent sheet having at least one printed image area on the first smooth side and a moisture cure adhesive layer over the printed image areas and non-image areas of the first smooth side, and the moisture cure adhesive layer being applied with a screen press through a screen; and combining the imaged transparent sheet on the adhesive layer side of the transparent sheet with a backing sheet by nipping the paired sheets with a nip roller. the lenticular card comprising: an imaged transparent sheet having a first front surface with a smooth region and a lenticulated region, and a second rear surface bearing an image; and a backing sheet bonded to the imaged transparent sheet with an adhesive, wherein the card has a thickness of from about 10 to about 40 mils.
 31. A lenticular card prepared by a process comprising: providing an imaged transparent sheet having a first smooth side and a second side with a lenticulated region, the transparent sheet having at least one printed image area on the first smooth side and a moisture cure adhesive layer over the printed image areas and non-image areas of the first smooth side, and the moisture cure adhesive layer being applied with a screen press through a screen; and combining the imaged transparent sheet on the adhesive layer side of the transparent sheet with a backing sheet by nipping the paired sheets with a nip roller, the lenticular card comprising: an imaged transparent sheet having a first front surface with a smooth region and a lenticulated region, and a second rear surface bearing an image; and a backing sheet bonded to the imaged transparent sheet with an adhesive, wherein the card has a thickness of about 30 mils plus or minus about 1.5 mils.
 32. A lenticular card prepared by a process comprising: providing an imaged transparent sheet having a first smooth side and a second side with a lenticulated region, the transparent sheet having at least one printed image area on the first smooth side and a moisture cure adhesive layer over the printed image areas and non-image areas of the first smooth side, and the moisture cure adhesive layer being applied with a screen press through a screen; and combining the imaged transparent sheet on the adhesive layer side of the transparent sheet with a backing sheet by nipping the paired sheets with a nip roller, the lenticular card comprising: an imaged transparent sheet having a first front surface with a smooth region and a lenticulated region, and a second rear surface bearing an image; and backing sheet bonded to the imaged transparent sheet with an adhesive, wherein the card has a finished trim size of about 3⅜ inches wide by about 2⅛ inches high.
 33. A lenticular card prepared by a process comprising: providing an imaged transparent sheet having a first smooth side and a second side with a lenticulated region, the transparent sheet having at least one printed image area on the first smooth side and a moisture cure adhesive layer over the printed image areas and non-image areas of the first smooth side, and the moisture cure adhesive layer being applied with a screen press through a screen; and combining the imaged transparent sheet on the adhesive layer side of the transparent sheet with a backing sheet by nipping the paired sheets with a nip roller, the lenticular card comprising: an imaged transparent sheet having a first front surface with a smooth region and a lenticulated region, and a second rear surface bearing an image; and a backing sheet bonded to the imaged transparent sheet with an adhesive, wherein the front surface of the transparent sheet is extruded and includes a front surface with a lenticulated region and a smooth region.
 34. A lenticular card prepared by a process comprising: providing an imaged transparent sheet having a first smooth side and a second side with a lenticulated region, the transparent sheet having at least one printed image area on the first smooth side and a moisture cure adhesive layer over the printed image areas and non-image areas of the first smooth side, and the moisture cure adhesive layer being applied with a screen press through a screen; and combining the imaged transparent sheet on the adhesive layer side of the transparent sheet with a backing sheet by nipping the paired sheets with a nip roller, the lenticular card comprising: an imaged transparent sheet having a first front surface with a smooth region and a lenticulated region, and a second rear surface bearing an image; and a backing sheet bonded to the imaged transparent sheet with an adhesive, wherein the surface area of the front surface of the transparent sheet is about one half lenticulated region and about one half smooth region.
 35. A lenticular card prepared by a process comprising: providing an imaged transparent sheet having a first smooth side and a second side with a lenticulated region, the transparent sheet having at least one printed image area on the first smooth side and a moisture cure adhesive layer over the printed image areas and non-image areas of the first smooth side, and the moisture cure adhesive layer being applied with a screen press through a screen; and combining the imaged transparent sheet on the adhesive layer side of the transparent sheet with a backing sheet by nipping the paired sheets with a nip roller, the lenticular card comprising: an imaged transparent sheet having a first front surface with a smooth region and a lenticulated region, and a second rear surface bearing an image; and a backing sheet bonded to the imaged transparent sheet with an adhesive, wherein the front surface is from about 10 to about 75 percent lenticulated region and from about 90 to about 25 percent smooth region.
 36. A process for making a lenticular card comprising: providing an imaged transparent sheet having a first side and a second side with a lenticulated region, the transparent sheet having at least one printed image area on the first side and a moisture cure urethane adhesive layer over the printed image areas and non-image areas of the first side; and combining the imaged transparent sheet on the adhesive layer side of the transparent sheet with a backing sheet by nipping the paired sheets with a nip roller wherein the resulting lenticular card is tamper resistant, tamper evident, or both.
 37. A process for making a lenticular card comprising: providing an imaged backing sheet having a first side and a second side, the backing sheet having a printed image on one side and a moisture cure urethane adhesive layer over the printed image areas and non-image areas of the imaged side; and combining the backing sheet on the adhesive layer side with the first side of a transparent sheet having a first side and a second side having a lenticulated region by nipping the paired sheets with a nip roller wherein the resulting lenticular card is tamper resistant, tamper evident, or both.
 38. A process for making a lenticular card comprising: providing an imaged transparent sheet having a first side and a second side with a lenticulated region, the transparent sheet having at least one printed image area on the first side and a moisture cure urethane layer over the printed image areas and the non-image areas of the first side; and combining the imaged transparent sheet on the moisture cure urethane layer side of the transparent sheet with a backing sheet by nipping the paired sheets with a nip roller.
 39. The process according to claim 38 wherein the moisture cure urethane layer is applied by a roll coater, spray coater, a curtain coater, or a screen press.
 40. The process according to claim 38 wherein the backing sheet includes a magnetic stripe.
 41. A process for making a lenticular card comprising: providing an imaged backing sheet having a first side and a second side, the backing sheet having a printed image on one side and a moisture cure urethane layer over the printed image areas and non-image areas of the imaged side; and combining the backing sheet on the moisture cure urethane layer side with the first side of a transparent sheet having a non-lenticulated first side and a second side having a lenticulated region by nipping the paired sheets with a nip roller.
 42. The process according to claim 41 wherein the moisture cure urethane layer is applied by a roll coater, spray coater, a curtain coater, or a screen press.
 43. The process according to claim 41 wherein the backing sheet includes a magnetic stripe. 